engineering support of planning and scheduling revsion 81
TRANSCRIPT
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Engineering Support for RefineryPlanning and Scheduling
Improve performance and marginswith aspenONE Engineering
Aspen Product Management
January 3, 2015
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Agenda
Why Engineering Support for Planning
Engineering Best Practices
Integrated Petroleum Supply Chain Workflow
Key Activities
Why aspenONE Engineering
Next Steps
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Why Engineering Support for RefineryPlanning and Scheduling
Improve Refining Marginswith accurate planning modelsthrough engineering models
Improve and sustain refinery margins
Faster and better feedstock selection
Accurate planning and scheduling models Agility in response to operational opportunities
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Engineering Best Practices
Feedstockselection
agility
PerformanceMonitoringof units andequipment
Planningmodel
updatesfor accuracy
Capital projectassessments
for optimaldesigns
Plantoperations
decision supportfor timely response
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Asset Engineering Lifecycle and Workflow
Integrating Engineering Business ProcessesEnables Best Practices
Research andDevelopment
ConceptualEngineering
BasicEngineering
DetailedEngineering
PlantOperations
Planning andScheduling
Develop Process
Technology
Select Process
Technology
Produce ConceptualProcess Design
Produce ConceptualEngineering Design
Construct and Pre-commission Plant
Commission andHandover Plant
Daily PlantOperations
MaintainEquipment
Procure and Control Equipment,Materials and Services
Produce DetailedEngineering Design
Identify Plant
Capital Projects
Produce DetailedProcess Design
FEED
Planning andScheduling
PlantOperations
Select Crude Oilsand Feedstocks
Issue OperatingTargets
Monitor and GuidePlant Performance
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Planning and Scheduling Model Updates
Challenge
Challenge Challenge
Impact
Planners andprocess engineerswork in silos
Engineering
models are neededas input to updaterefinery wideplanning models
Reduced predictivecapability andproduct quality
Variation between
plan vs. actual
Lost Margins
Higher margins
with optimal yields and on-time,on-spec performance
Solution
Easier updating of
planning and schedulingmodels to reflect actual
plant performance
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Unique to aspenONE
Workflow toupdate planning
models usingrigorous models
Ease of usewith calibrationtools and links
between models
Supportcollaboration
between engineersand planners
Businessapplication
access by plannersand schedulersthrough Excel
Collaborative workflow to update planning and scheduling models
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Refinery activityHeadquarters activity
Market
Demand
Forecasting
Refinery Planning
Refinery
Scheduling
Production Plan
Primary Distribution Scheduling
(depot inventory management)
Distribution PlanningMarket Forecast
Constrained Forecast
Refinery
Production targets
Distribution & Exchange Plan
Market Forecast
Scheduled Movements
to/from Refineries
Secondary
Distribution
Scheduling
Retail Demand(by terminal)
Blend
Scheduling
& optimisation
Trading
Accounting
(SAP)
Deals
Sales History
Production Schedule
Actualised
movements
Advanced Process Control
Process Unit
Set-pointsBlend recipes
Pipeline
simulation &
scheduling
Batch
confirmation
Batchnomination
Integrated Petroleum Supply Chain (IPSC)
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Refinery activityHeadquarters activity
Market
Demand
Forecasting
Refinery Planning
Refinery
Scheduling
Production Plan
Primary Distribution Scheduling
(depot inventory management)
Distribution PlanningMarket Forecast
Constrained Forecast
Refinery
Production targets
Distribution & Exchange Plan
Market Forecast
Scheduled Movements
to/from Refineries
Secondary
Distribution
Scheduling
Retail Demand(by terminal)
Blend
Scheduling
& optimisation
Trading
Accounting
(SAP)
Deals
Sales History
Production Schedule
Actualised
movements
Advanced Process Control
Process Unit
Set-pointsBlend recipes
Pipeline
simulation &
scheduling
Batch
confirmation
Batchnomination
Integrated Petroleum Supply Chain (IPSC)
Engineering Models Support
Planning & Scheduling
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Example: A Recent IPSC Project
Global Orion
PPIMS
LocalORION/MBO
AtOMS
Advisor
RefSys PSMA
PublishedSchedule (13)
Tank andVessel
MovementsData
Tank Info,Products, Units
Stream flows &Qualities from
IP21
From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data
To Oracle
Financials
From IP.21:
process and lab
data
Plan Data
From IP.21: lab
data
ReconciledData
PPIMS
LocalORION/MBO
AtOMS
Advisor
RefSys PSMA
PIMS to Orion(11)
Orion Imports (12)
Tank andVessel
MovementsData
Tank Info,Products, Units
From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data
From IP.21:
process and lab
data
Plan Data
From IP.21: lab
data
ReconciledData
PPIMS
LocalORION/MBO
AtOMS
Advisor
RefSys PSMA
Tank andVessel
MovementsData
Tank Info,Products, Units
From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data
From IP.21:
process and lab
data
Plan Data
From IP.21: lab
data
ReconciledData
XPIMS1. Mid-Term
Planning
2. Short-Term
PlanningIRT
InventoryProjections (9)
3. RefineryScheduling
DSS
To Oracle
Financials
To Oracle
Financials
4. Operations
Execution
5. Production Accounting
6. Operational PerformanceManagement
PS EM
RBV ODM
Data Loading
Line of Pallots
MAA MAB SHUMOG
XPIMS
KPC Int Mktg
$
Ref MAA, MAB, SHU
Demand,Prices (1)
Demand (2)
ShutdownDays (3)
Sales, Target Inventory (4)
IRT (5)
Shares Same DataBase
KPC Supply Ops
Nominations
Shipment Events (Vol, Prd, Dem, etc)
Finalised Feasible Shipments to Local Orion (7)
AggregatedDemand (8) Aggregated
Demand (8)AggregatedDemand (8)
InventoryProjections (9)
InventoryProjections (9)
Global Targets: Sales, IRT, Capacity Inventory to Local Plan (10)
PIMS to Orion(11)
PIMS to Orion(11)
Orion Imports (12)Orion Imports (12)Published
Schedule (13)Published
Schedule (13)
Reuters, Platts, etc
Component & Product Prices (14)
Nominations
Stream flows &Qualities from
IP21
Stream flows &Qualities from
IP21
KPC Supply Ops
Supply Program
HQ Refinery 1 Refinery 2 Refinery 3
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Example: A Recent IPSC Project
Global Orion
PPIMS
LocalORION/MBO
AtOMS
Advisor
RefSys PSMA
PublishedSchedule (13)
Tank andVessel
MovementsData
Tank Info,Products, Units
Stream flows &Qualities from
IP21
From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data
To Oracle
Financials
From IP.21:
process and lab
data
Plan Data
From IP.21: lab
data
ReconciledData
PPIMS
LocalORION/MBO
AtOMS
Advisor
RefSys PSMA
PIMS to Orion(11)
Orion Imports (12)
Tank andVessel
MovementsData
Tank Info,Products, Units
From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data
From IP.21:
process and lab
data
Plan Data
From IP.21: lab
data
ReconciledData
PPIMS
LocalORION/MBO
AtOMS
Advisor
RefSys PSMA
Tank andVessel
MovementsData
Tank Info,Products, Units
From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data
From IP.21:
process and lab
data
Plan Data
From IP.21: lab
data
ReconciledData
XPIMS1. Mid-Term
Planning
2. Short-Term
PlanningIRT
InventoryProjections (9)
3. RefineryScheduling
DSS
To Oracle
Financials
To Oracle
Financials
4. Operations
Execution
5. Production Accounting
6. Operational PerformanceManagement
PS EM
RBV ODM
Data Loading
Line of Pallots
MAA MAB SHUMOG
XPIMS
KPC Int Mktg
$
Ref MAA, MAB, SHU
Demand,Prices (1)
Demand (2)
ShutdownDays (3)
Sales, Target Inventory (4)
IRT (5)
Shares Same DataBase
KPC Supply Ops
Nominations
Shipment Events (Vol, Prd, Dem, etc)
Finalised Feasible Shipments to Local Orion (7)
AggregatedDemand (8) Aggregated
Demand (8)AggregatedDemand (8)
InventoryProjections (9)
InventoryProjections (9)
Global Targets: Sales, IRT, Capacity Inventory to Local Plan (10)
PIMS to Orion(11)
PIMS to Orion(11)
Orion Imports (12)Orion Imports (12)Published
Schedule (13)Published
Schedule (13)
Reuters, Platts, etc
Component & Product Prices (14)
Nominations
Stream flows &Qualities from
IP21
Stream flows &Qualities from
IP21
KPC Supply Ops
Supply Program
HQ Refinery 1 Refinery 2 Refinery 3
Engineering Support for Planning
and Scheduling is built into this project
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Refinery Plant Data enters IPSC via theEngineering Models (see terms next slide)
RTOReal Time 24/7 Automatic
Data Collection
APCDMCplus
Real Time Data Base (IP.21, PI, PHD)
Simplified Modelsto Aspen PIMS &
Scheduler
Plant Targets(APC setpoints)
ASW Link
Plant DCS
ASWOn DemandManual DataCollection
AODReal Time 24/7Automatic Data
Collection
To IPSC From IPSC
Aspen RefSYS FlowsheetsEngineering Models forPlanning and Scheduling Support with
Data Reconciliation and Calibration
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Planning and Scheduling Support WorkflowsStart with Aspen RefSYS*
Aspen RefSYS Flowsheets
Aspen PIMS andAspen Petroleum Scheduler
* The new name for Aspen RefSYS is Aspen HYSYS Petroleum Refining
Excel
Assay Tables forCrude Distillation
Case Study/Excel orSwing Cut Utility
Workflow 1 Excel
LP Submodelsfor Reactors
Case Study/Excel orPIMS Support Utility
Workflow 2
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Planning and Scheduling Support Workflowswith PIMS to Petroleum Scheduler Integration
Workflow 2
Aspen RefSYSFlowsheets
Aspen PIMS
Excel
Assay Tables forCrude Distillation
Case Study/Excel orSwing Cut Utility
Workflow 1 Excel
LP Submodelsfor Reactors
Case Study/Excel orPIMS Support Utility
Aspen PIMS
Aspen Petroleum
Scheduler
Aspen Petroleum
SchedulerWorkflow 3V7.3 Utilities
Workflow 4SMC file transfer
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Crude Assay Management
ChallengeChallenge ChallengeImpact
Characterizingeach crudesproperties andcomposition is
time consuming Blending crudes
into a singlefeedstockcomplicates settingoperational targets
Errors can havesignificant impacton simulationresults
Lost opportunitycrude oils
Lost Margins
Higher marginsExploit opportunity feedstocksand improve operating plans
Solution
Improved crude oil
blending to increaseaccuracy and reduce
simulation times
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Why is Crude Oil Characterization Important?
Petroleum refinery profit margins are under great pressure
Crude oil prices and product prices move independentlydestabilizing profit margins
Feed and product costs must be well understood to protect
profit margins
Crude oil compositions must be well defined to correctlyprice feed stocks and products
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How does Crude Oil CharacterizationImprove Profits?
Crude oil characterization data is used in three main ways: Engineering models (Aspen HYSYS Petroleum Refining)
Planning models (Aspen PIMS)
Scheduling models (Aspen Petroleum Scheduler)
Engineering models confirm crude distillation units cansuccessfully process purchased crude oils
Planning models select optimal crudes oils for refinery
Scheduling models assure smooth and predictable delivery ofproducts
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Where is Crude Oil Characterization Done?
Planning and Scheduling Support tools Third party products
Flowsheet simulators
Aspen HYSYS Oil Manager Aspen RefSYS MacroCut
Aspen Plus (ADA)
In house crude cutting programs
Large oil companies
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Crude Oil Characterization Methods Used inAspen HYSYS and Aspen RefSYS
Feed
StreamModel
Lab Data:
Gravity,Distillation,
etc.
RefSYS
Macro CutInput
Table
RefSYSAssay
Manager
HYSYS
Oil
Manager
3rdparty
assay managers
Other crude
cutting programs
RefSYS Macro Cut
Input Table
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Crude Oil Characterization Usage
Feed
Stream
Model
Lab Data:
Gravity,
Distillation,
etc.
RefSYS
Macro Cut
Input
Table
RefSYS
Assay
Manager
HYSYS
Oil
Manager
3rdparty
assay managers
Other crude
cutting programs
RefSYS Macro Cut
Input Table
HYSYS/RefSYS
Fractionation
Models
RefSYS cases
confirm crude
unit can
process crude
Yields
& Properties
for PIMS
Yields
& Properties
for Petroleum
Scheduler
Fractionation models re-assemble narrow range hyposinto wider range product cuts for PIMS assay tables